SAFETY IN THE ZONE

How Xwatch and Leica are Redefining Construction Protection

Bringing precision and protection together, Xwatch and Leica’s innovative integration is making worksites safer, smarter, and more efficient.

Xwatch Safety Solutions, part of Hexagon and based in Wimborne, Dorset, UK, is a global leader in intelligent safety systems for construction machinery. Designed to enhance operator awareness and machine control, Xwatch systems provide advanced height, slew, and Rated Capacity Indicator (RCI) restrictions, delivering industry-leading protection for people, plant, and infrastructure. Known for their ease of installation, intuitive operation, and seamless integration with machine control technology, Xwatch systems are widely adopted across OEMs, retrofitting solutions, and global construction sites.

"THIS GIVES OPERATORS THE ABILITY TO WORK SAFELY AROUND AVOIDANCE ZONES ACROSS AN ENTIRE SITE.”

With dedicated divisions in Australia, the Americas, and France, and a growing international dealer network, Xwatch continues to expand its reach, ensuring expert support wherever customers operate. Following its acquisition by Hexagon, Xwatch is driving innovation in connected safety technology, bringing smarter solutions to sites worldwide and helping contractors, hire companies, and major construction firms reduce risk, improve productivity, and meet the highest safety standards.

The Awesome Earthmovers team visited the Leica Geosystems training school in Whitchurch, Shropshire, to see Xwatch Safety Solutions in action and explore its collaboration with Leica. The two companies have developed an integrated safety and machine control solution that allows users to create or import 3D avoidance zones—both above and below the surface – directly within the Leica MC1 machine control software. The systems are connected via a CAN bus communication channel, creating one of the world’s first fully integrated safety and productivity solutions in a 3D environment. This development enables greater control and precision on construction sites, helping to safeguard workers, machinery, and infrastructure.

At the Leica Geosystems training facility, known as “The Sandpit,” the AE’s team watched a JCB 245XR in action, fitted with Leica 3D machine control and Xwatch XW5 with Track Lock. The demonstration highlighted how these technologies work together to improve safety and efficiency. Warren Wilkinson of Explore Plant & Transport Solutions, based in St Neots, Cambridgeshire, supplied the machine.

Xwatch Sales Director Dan Leaney explained how the integration works, stating, “We connected an XW5 – a height, slew, and Rated Capacity Indicator (RCI) system – to the Leica MC1 machine control software. The system provides a virtual wall with height, slew, and depth control, allowing recognition of cables and utilities from the MC1 software. This gives operators the ability to work safely around avoidance zones across an entire site.” He described the system as a major step forward in linking safety and machine control, making excavator operations more controlled and precise.

Operators can define or import avoidance zones via the in-cab Leica MCP80 panel. If the machine approaches these zones, hydraulic functions automatically slow down or stop to prevent entry. The system is intuitive and easy to use, with the added capability of disabling the machine’s tracks using Track Lock.

Track lock is a feature within the Xwatch XW series so when height and slew limits are set or a 3D avoidance zone has been reached, it will stop the machine from tracking.

This prevents movement into restricted areas such as environmental sites, underground utilities, and power cables, as well as overhead obstructions, pedestrian walkways, live carriageways, and public roads.

Leica Geosystems and Xwatch first announced their collaboration in 2021 with the introduction of the Leica iCON PA80 avoidance solution, integrated with the Xwatch XW4 and XW5 series safety systems. This new system builds on that foundation, helping construction sites minimize accidents, protect existing infrastructure, and reduce costly delays. The ability to set up 3D avoidance zones ensures safer operations near power lines, underground services, and high-risk areas.

This fully integrated system combines Xwatch’s XW5 Series with Leica’s MC1 machine control software, delivering a streamlined approach to safety and efficiency on modern worksites. The 3D Avoidance Zone system offers flexible options for defining restricted areas, allowing operators to tailor safety zones to specific site requirements. Zones can be set manually using the excavator bucket to log points or selected from a 3D project file, ensuring precise boundaries and alignment with digital construction plans. Underground hazards can also be defined using underground detection model files, providing essential protection around buried utilities and critical infrastructure. Once set, the system continuously monitors machine movements, ensuring compliance with defined boundaries while requiring minimal operator input.

The integration of Xwatch and Leica technologies delivers a fully connected machine control and safety solution. The Xwatch hydraulic control box and in-cab connections to the Leica MCP80 panel provide a seamless interface, allowing operators to focus on their tasks while the system actively prevents hazardous movements. As the machine approaches an avoidance zone, proportional hydraulic control slows its speed before stopping completely. The Leica MC1 software provides visual warnings that require operator confirmation before continuing work, ensuring a controlled and informed response to potential hazards.

For contractors, plant hire companies, and project managers, this system offers more than just safety – it reduces downtime, prevents costly mistakes, and improves site management. By integrating controlled safety features into everyday operations, businesses can protect their workers, reduce administrative burdens, and operate more efficiently. The collaboration between Xwatch and Leica Geosystems has introduced a new level of precision and control, giving construction professionals the confidence to work more safely and effectively on-site.

What’s new from Xwatch Safety Solutions

Xwatch Safety Solutions, part of Hexagon, is launching the MK2 at Bauma Munich 2025 on the Hexagon stand, setting a new benchmark in machine control and safety. MK2 is the evolution of MK1 – staying true to the Xwatch ethos: keep moving forward, never stand still. Everything that made MK1 an industry leader remains, but MK2 refines and enhances every aspect – from installation simplicity to global compatibility.

The installation has been significantly improved, with the time reduced by 30%, making it faster and smoother to fit. As Xwatch expands into new global markets, installers and operators unfamiliar with the system needed an approach that was simpler, more intuitive, and easier to adopt with confidence – and MK2 delivers. The new system is even more adaptable and user-friendly, reducing downtime for plant hire companies and contractors.

It retains all the capabilities of MK1, including height and slew restriction, Rated Capacity Indicator (RCI), and the full suite of Xwatch safety features across the XW1, XW2, XW3, XW4, and XW5 models. Every detail has been refined to make it easier to install, more efficient, and more versatile while maintaining Xwatch’s reputation for unmatched safety technology.

New enhancements include revolutionary proportional motion control when driving electric over hydraulic valve blocks (Pat. Pending), a significant breakthrough in precision and efficiency. Graphics have been completely reworked, creating a more visually friendly and intuitive monitor interface. Its multi-lingual capability ensures the system is global. MK2 is telematics-ready for connected construction sites and is more compact, freeing up in-cab space.

Paving the way for future compatibility

Due to Xwatch’s long-term OEM machine integration strategy, it is built to be compatible with various OEM displays. This minimises the need for additional hardware in the cab and ensures seamless integration for manufacturers adopting the system.

No competitor offers what Xwatch MK2 does – its combination of safety, ease of use, installation efficiency, and OEM integration is unmatched. Xwatch continues to push innovation, reinforcing its position as the leader in construction safety technology.

“OUR SYSTEM IS A GAME-CHANGER IN CONSTRUCTION SAFETY, SIGNIFICANTLY REDUCING THE RISK OF ACCIDENTS WHILE MAKING IT INCREDIBLY EASY FOR OPERATORS TO WORK EFFICIENTLY.”